NAME : NURUL AIN BINTI SUHAIMI MATRIC NUMBER : B011010117 COURSE : BACHELOR OF POWER ELECTRONICS & DRIVES YEAR : 2013 PROJECT TITLE : DEVELOPMENT OF AC-DC CONVERTER SUPERVISOR : NORHAZILINA BT BAHARI NAME
DEVELOPMENT OF AC-DC CONVERTER Submitted By: NURUL AIN BINTI SUHAIMI B011010117 This Technical Report for Final Year Project is submitted to Faculty of Electrical Engineering, Universiti Teknikal Malaysia Melaka In partial to fulfilment of Bachelor of Power Electronics & Drives Engineering. Faculty of Electrical Engineering (FKE) UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
ii STUDENT'S DECLARATION I hereby declare that this thesis entitled "Development of AC-DC Converter" is the result of my own research except as cited in the references. This is project is adequate in terms of scope and quality for the award of the degree of Bachelor of Power Electronics & Drives Engineering. Signature : Name : NURUL AIN BINTI SUHAIMI ID Number : B011010117 Date : 18/JUNE/2013
iii SUPERVISOR'S DECLARATION I hereby declare that I have checked this project and in my opinion, this project is adequate in terms of scope and quality for the awards of the Degree of Bachelor of Power Electronics & Drives Engineering. Signature : Name : NORHAZILINA BINTI BAHARI Position : LECTURER Date : 18/JUNE/2013
iv ACKNOWLEDGEMENT Assalammualaikum w.b.t. Firstly, I would like to thank almighty God for the strength and blessings. I would like to thanks a lot to my supervisor Mrs. Norhazilina Bte Bahari for always supporting along with her guidance through this one year final year degree project development. Secondly, I would like to thanks my friends who helped me directly or indirectly. They always give support, generate idea and also sharing knowledge together so that I understand better and could complete my analysis report with flying colours. Finally, I would also like to thank my parents. Even though both of them far away, but they always give me support to complete my degree and want me to shows good performance in representing my final year project. Their support gives me the strength to endure this final year project and successfully complete it.
v ABSTRACT Power electronics engineering nowadays gaining attention such example advantage of small components that can produce large benefits in quality of power production. If the circuit is designed to take into account all possible advantages and disadvantages of a parameter, it can have an impact on the resulting product. Structured circuit LED power previously divided into two stages, single stage and two stage structures has been in formation by previous researchers for the development of power electronics areas. Converter is a device that converting the unregulated DC input to a controlled DC output with a desired voltage. The applications that use the converter is switched-mode power supply (SMPS), DC motor control and battery charges. Two major sections that will analyse are non-isolated DC- DC converter and isolated DC-DC converter. Whereas in this project there is a combination between the use of isolated and non-isolated. The main purpose of this project is produced to meet the objectives of producing AC-DC converter that is capable of producing large scale power and is suitable for all current applications. Experiment was conducted to test whether the three circuits can meet the conditions of producing large power output and efficiency of the best circuits. Tested power output circuit by selecting 36W power LEDs connected in series based on LED configuration. Calculations have been performed to identify products capable of meeting the specified requirements. Analysis done by using Matlab Simulink software versions R2010a. The output voltage should produce 24V. Among all the circuits, the best circuit performance is interleaved single-stage flyback converter. The results of the analysis carried out, total harmonics distortion value is 15.94% and the efficiency of the circuit is 15.07%.
vi ABSTRAK Bidang kejuruteraan elektronik kuasa pada masa kini semakin mendapat perhatian sebagai contoh kelebihan komponen kecil yang boleh menghasilkan faedah yang besar dalam kualiti pengeluaran kuasa. Jika litar direka dengan mengambil kira segala kemungkinan kelebihan serta kekurangan sesuatu parameter itu, ia mampu memberi impak terhadap produk yang bakal dihasilkan. Litar berstruktur kuasa LED yang sebelumnya terbahagi kepada dua peringkat iaitu struktur satu peringkat dan juga struktur dua peringkat telah di formasi oleh penyelidik yang terdahulu bagi membantu perkembangan bidang keberhasilan elektronik kuasa. Penukar adalah peranti yang menukarkan input DC dikawal kepada output DC dikawal dengan voltan yang dikehendaki. Aplikasi yang menggunakan penukar adalah bekalan dihidupkan-mode kuasa (SMP), DC motor kawalan dan caj bateri. Dibahagikan kepada dua bahagian yang tidak terpencil DC-DC penukar dan terpencil DC-DC penukar. Manakala dalam projek ini terdapat gabungan antara penggunaan terpencil dan bukan terpencil. Tujuan utama projek ini dihasilkan adalah bagi memenuhi objektif iaitu menghasilkan penukar AC-DC yang mampu mengeluarkan skala kuasa yang besar dan bersesuaian untuk semua aplikasi semasa. Experimen dijalankan bagi menguji samada ketigatiga litar dapat memenuhi syarat yang ditetapkan iaitu menghasilkan keluaran kuasa yang besar dan memberi kecekapan litar yang terbaik. Keluaran kuasa litar diuji dengan memilih kuasa 36W LED yang disambung secara siri berdasarkan konfigurasi LED. Pengiraan juga dilakukan bagi mengenalpasti keluaran mampu memenuhi syarat yang ditetapkan. Analisis dilakukan dengan menggunakan perisian Matlab Simulink versi R2010a. Voltan output harus menghasilkan 24V. Antara semua litar, prestasi litar terbaik adalah interleaved penukar flyback satu peringkat. Hasil dari analisis yang dijalankan, jumlah keseluruhan harmonik nilai gangguan terganggu adalah 15.94% dan kecekapan litar adalah 15.07%.
vii TABLE OF CONTENTS ACKNOWLEDGMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF TABLES LIST OF CHART LIST OF FIGURE LIST OF SYMBOLS LIST OF APPENDIX iv v vi vii x xi xiii xiv xv 1 CHAPTER 1 INTRODUCTION 1.1 Project Background 1.2 Problem Statement 1.3 Project Objective 1.4 Project Scope 1.5 Project Methodology 1 2 3 3 4 2 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 2.2 First Research Development of AC-DC Converter for laboratory power amplifier 2.3 Second Research An interleaved single stage flyback 2.4 Third Research New Control method of An interleaved single stage flyback 6 7 8 10 3 CHAPTER 3 THEORY
viii 3.1 What is Converter? 3.1.1 Concept of Converter in Power Electronics Non-isolated DC-DC Converter 3.2 What is Flyback Converter 3.3 Total Harmonics Distortion 3.4 Efficiency 13 14 18 21 22 4 CHAPTER 4 METHODOLOGY 4.1 Introduction 4.2 Circuit Design using software Matlab 4.3 Circuit Simulation 4.3.1 Switching Device 4.3.2 Rectifier 4.3.3 Flyback Converter 4.3.4 DC-DC Converter 4.3.5 Resistance Load 23 24 25 27 28 29 31 5 CHAPTER 5 RESULT AND DISCUSSION 5.1 Introduction 5.2 Simulation circuit of single-stage structure 5.3 Result and Analysis of single-stage a) THD and Power factor b) Efficiency 5.4 Simulation circuit of two-stage structure 5.5 Result and Analysis of two-stage a) THD and Power factor b) Efficiency 5.6 Simulation circuit of Interleaved Single-Stage Structure Flyback Converter 5.7 Result and Analysis of ISSF a) THD and Power factor 32 33 34 35 36 38 40 41 43 45
ix b) Efficiency 5.8 Discussion 46 50 6 CHAPTER 6 CONCLUSION & RECOMMENDATION 6.1 Conclusion 6.2 Recommendation 51 52 7 CHAPTER 7 REFFERENCES 53 8 APPENDIX 55
x LIST OF TABLES TABLE TITLE PAGE 4.0 Comparison of MOSFET and IGBT 25
xi LIST OF CHART TABLE TITLE PAGE 1.5.4 Research Methodology Flow Chart 5
xii LIST OF FIGURES FIGURE TITLE PAGE 2.2.1 Two stage cascaded converter with PFC 7 2.2.2 Circuit for two-stage-cascaded converter with PFC 8 2.3.1 Power Stage of LED driver 9 2.3.2 Efficiency 10 2.4.1 Interleaved single-stage flyback converter 11 2.4.2 LED configuration 12 3.1.1 Buck Converter 14 3.1.2 Waveform of Buck Converter 15 3.1.3 Circuit Illustration when Switch Close 16 3.1.4 Circuit Illustration when Switch Open 16 3.2.1 Schematic of a Flyback Converter 18 3.2.2 Switch being closed 19 3.2.3 Switch being open 20 3.4.1 Ideal sine wave 21 3.4.2 Distorted Waveform 21 4.1 Mathwork Matlab 24 4.2 Step in developing switching MOSFET 25 4.3 Mosfet configurations in Matlab 26 4.4 Simple circuit of half-wave rectifier 27 4.5 Diode Bridge Configurations in Matlab 27 4.6 Single stage flyback converters 28 4.7 Flyback converter blocks in Matlab 29 4.8 Buck Converter 30 4.9 Two-stage flyback converters in Matlab 30 4.10 36W Flood LED Load 31
xiii 5.1 Simulation circuit single-stage 33 5.2 FFT tools 34 5.3 THD value of single-stage structure 35 5.4 Graph of power output and power input 36 5.5 Graph of voltage output 37 5.6 Simulation circuit second-stage 39 5.7 THD value of two-stage structure 40 5.8 5.9 5.10 5.11 5.12 5.13 Graph of power output and power input Graph of voltage output Simulation circuit of ISSF THD value of ISSF structure Graph of power output and power input Graph of voltage output 41 42 44 45 46 47
xiv LIST OF SYMBOLS DC - Direct current CCM - Continuous Conduction Mode DCM - Discontinuous Conduction Mode ISSF - Interleaved Single Stage Flyback I/O - Input / Output THD - Total Harmonics Distortion Hz - Hertz FFT - Fast Fourier Transform SMPS - Switched Mode Power Supply AC - Alternating Current POL - Point Of Load PF - Power Factor Lm - Magnetizing Inductance ɳ - Efficiency LED - Light Emitting Diode sec - Seconds % - Percentage
xv LIST OF APPENDIX Appendix A: Flow Chart of Project Activities Appendix B: Project Schedule of Project Activities (Gantt chart) Appendix C: TURNITIN Report must be attached
xvi Appendix A Start Planning Data collection / Literature Review Development of design circuit and simulation Design Circuit with selected parameter value Integrated / Implement Observe the simulation Success? No Analysis and writing End Yes
xvii Appendix B Gantt chart Project Planning List major activities involved in the proposed project. Indicate duration of each activity to the related month(s). 2012 2013 Project Activities Sept Oct Nov Dec Jan Feb Mac April May Topic discussed with lecture and the project to be well understood Details collected regarding topic, information and supervisor briefing every weeks and literature review studied The proposal completed for FYP 1 and prepared for the seminar presentation Simulation done using Matlab tools software Simulation design for load configuration Started doing improvement of the simulation design circuit Software part completed and tested Report for FYP 2 completed
Appendix C xviii
CHAPTER 1 INTRODUCTION This chapter discuss an overview of the project background, activities and goals containing a common description of what is expected to be done within the project and will prior to the implementation process for the targeted goal. It will include the primary focus, a list of key reasons for launch, a very common description of how to perform this project and plain explanation of the desired outcomes. 1.1 Project Background This project purpose of design and develop a converter 240-24 V for general purpose application. Project consists of analyze and develop an interleaved single stage flyback converter with wide output power range. By looking to the scenario nowadays modern electronics system surrounding us requires high-quality, small, light weight, reliable and efficient power supplies that construct operation of voltage or current divider. However all goods will faces the kind of problems such as limited power to output voltage and smaller than input voltage and also power density turns low because low frequency are required (50-60 Hz) for filters and line transformers. Another problems occur in the electronics device is Electromagnetic Interface (EMI) [15]. EMI is the leakage of electronics radiation from a device that can cause problem with electronic circuitry and communication systems. To reduce the EMI levels is to determine all the source of EMI or either develops alternative technologies [6]. Good factor that considering the electronics device is low Total Harmonics Distortion (THD) even the output power low. Total harmonics distortion is the measurement of all harmonics components of the voltage or current waveform against the fundamental component [16]. The purpose is to characterize the power quality of the systems. To make sure the system works fluently without
2 interruption, power electronics switches using IGBT s perform operate at high frequencies, lighter in the system. Analyze using Matlab Simulink comparison will be proving in term of simulation development. As the student that field in this power electronics courses, it is kind of responsibility to upgrade the system that we use now days so that it will make life easier, compact and sophisticated to young and future. 1.2 Problem Statement From the survey on research of paper in power electronics systems, most of the equipment of power electronics usually faces the electromagnetic interface (EMI) at the input power stage. EMI produces in two forms such in the form of radiated, noise travels through the air. In this analysis will focus on conducted EMI which noise travel in electrical conductors, wires, electronics component for example capacitors, resistors, transformer, inductors, semiconductors and etc. Other than that is about the total harmonics distortion (THD). The Total Harmonics Distortion is the summation of all harmonics components of the voltage or current waveform compared against the fundamental component of the voltage or current wave. Harmonics distortion for general can increase the current in power system which results higher temperatures in distribution transformers and neutral conductors. Recently, the required value of total harmonics distortion (THD) is less than 10% in the industry. Thus, this project state that single-stage and two-stage structure faces problem of low efficiency and low power factor, as the solution of these problems, an interleaved flyback converter that can handle high output power, good PF and THD will be analyse.
3 1.3 Project Objective Below show a few objectives to be accomplished in the end of this project: To design and develop wide output power range for general purpose application. To provide the high efficiency of the circuit. To provide the low harmonic distortion (THD) even the output power low. To analyze the difference between the circuits configurations. 1.4 Project Scope The project scope will cover aspects such as design and develop a converter using Matlab / Simulink tools. Project cover of analyze mainly focus on an interleaved single stage flyback with wide output power range. The system also use converter switching elements to increase switching speed, allowing the cost of circuit magnetic to be reduced and keeping switching losses to a minimum. The systems also analyze the circuit parameter such without filter, with filter and also two-stage structure of driver. Monitoring the several circuit performance by looking of good power factor, low total harmonic distortion and high efficiency, this system will implement to the application and will fit to the general purpose application so that it help consumer to achieve high quality of power range better from our present technology.
4 1.5 Project methodology The methodology involves in this project including of : a) Preparation (planning) This is the earlier stage thus it needs a lot of research and observing related information about the project. This stage is to recognize what is the problem occur when relate to the power electronic device. Also to identify the solution by comes out with the problem statement and problem scope. As the result of this stage, the outline objective, scope and expected result will be determined. b) Data collection phase Review the problem of the circuit system and self study of the description related due to the component use in the project. All the information that gain from supervisor was list down to improve the research observe. Also source from the internet, supportive comment and reference book were included also. c) Development ( Design circuit & simulation ) Construct the circuit diagram in the Matlab / Simulink tools. The aim of this stage is to view the switching elements of the proposed control method requirement. The observing result was classified for further progress. Analyze consist of power factor, total harmonic distortion and efficiency. Design the switching converter. d) Implementation Run the Matlab tools and make an observed if it is compulsory and make step of evaluation. Refer to the supervisor for further step of progress. After satisfied with the result, next do analyses with the data obtain and write the final full report.
5 Start Planning Data collection / Literature Review Development of design circuit and simulation Design Circuit with selected parameter value Integrated / Implement Observe the simulation Success? No Analysis and writing End Yes Chart 1.5.4 Research Methodology Flow Chart